Pre-cast building unit or slab and method of assembling same



May 10, 1938. c. M. HUNTIN GTON 2,115,946

PRE-CAST BUILDING UNIT 0R SLAB AND METHOD OF ASSEMBLING SAME. Filed July9, 1937 2 Sheets-Sheet 1 May 10, 1938. HUNTINGTQN 2,116,946

PRE-CAST BUILDINQUNIT OR SLAB AND METHOD OF ASSEMBLINGSAMH Filed July 9.1957 2 Sheets-Sheet 2 ,7 7L c a. q 8 7.9

9 m wa y/ e Mia/ 117a m 'ml in mm Patented May 10, 1938 FEE-CASTBUILDING UNIT 01!. SLAB AND- METHOD OF ASSEMBLING SAME Charles M.Huntington, Ladoga, Ind; Application July 9,1937, Serial No. 152.847

17 Claims.

This invention relates to pre-cast buildingunits orslabs and method ofassembling same,

and pertains more particularly to the use of av plurality of such unitsor slabs in double wall constructions for buildings, enclosures etc.

The primary important object of the invention is to provide an improvedpre-cast slab and method of assembling a pluralityof such slabs, wherebyany structure iormedthereof, embodies strength, insulating and moistureproof qualities.

Another important object of the invention is to provide pre-cast slabsof the above character and method of, assembly thereof, whereby a doublewall structure may be rapidly and economically erected at a minimum costof labor and materials and with a considerable saving in time. i

A further important object of this invention is to provide a method andmeans of assembling pre-cast slabs of theabove character whicheliminates mathematical precision in the casting of the latterwhen sameare composed of comparatively coarse aggregate. A still furtherimportant object of this invention is to provide pre-cast slabs of theabove character, whereby they may be readily assembled into a doublewall structure having passages therein for the reception of piping,wirin insulation, etc., or which may be utilized for ventilating or airconditioning purposes.

These and other important objects and advane tages of the presentinvention wfll be readily obvious throughout the course of the following35 specification and accompanying drawings, in

which v Figure 1 is a fragmentary perspective view of a portion of adouble wall constructed in accordance with the present invention; 40Figure 2 is a-perspective view of one of'th units or slabs with partsbroken away to disclose one form of reinforcement therefor;

Figure 3 is a sectional view taken on line 3-3 of Figure 1, showing thedetachable guide 45 member and the bracing therefor;

Figure 4 is a fragmentary horizontal sectional view taken through one ofthe detachable guide members and a portion of the surrounding wall,

the dotted lines indicating the position to which 50 the guide member isrotated preparatory to removal from the wall; c

Figure 5 is a fragmentary horizontal sectional view similar to Figure 4with the guide member removed and the space formerly occupied by the 55-latter filled with a plastic material; and

Figure 6 is a'fragmentary perspective view of the footing, guide pin andguide member for aligning the slabs during the construction of aReferring more speciflcallyto the drawings. 5 'wherein like referencecharacters refer to similar and like parts throughout the several views,

i indicates a unit or slab, of preferred form which, together withsimilar or other slabs or units, are assembled to provide an improved 10double walled structure. a e

As shown in-Figure 2, the slab or unit I is precast of concrete orother. suitable plasticmaterial in a horizontally disposed open top mold,(not shown), and during such casting is provided with 15 an embeddedmetallic reinforcing element 2 of open mesh fabric or the like. Whilesuch slabs are preferably cast in a substantially flat rectangularconfiguration, some may be formed in any other desired shape to meetvarious prob- 20 lems encountered in buildingconstructions.

The molds (not shown), in which slabs I are cast, are formed so as toprovide one face of the slabs, intermediate the ends of the latter,,with a pair of integrally cast and vertically extending 25 spaced ribs3, which results in the formation of a substantially U-shaped channel 4substantially centrally located with respect to the ends of said slabs.Also on the same side or face of the slab, and equally spaced inwardlyfrom each 30 of its ends and from the ribs 3, is an integrally castvertically extending rib 5 substantially semi- U-shaped providing agroove lywhich, with a corresponding groove in an adjacent slab, forms achannel corresponding tochannel 4. All of the ribs 3 and 5 are ofgreaterwidth at their point of connection with the slab body, and it ispreferred that the distance from the center of the rib i to the end ofthe slab or unit shall equal the distance from the center of the channel4 to the center of either rib 3, but, any arrangement of ribs whichprovides the construction and results hereinafter described and claimedmay be employed. 1 I n The slabs are further proVided adJacent the outersides of the ribs 3 and, inner sides of the ribs 5, with verticallyaligned and spaced openings 6 extending transversely therethrough. 'Iheopenings I, of each slabandits opposed slab in a double walledconstruction, are adapted to receive temporary tie-rods I, the latterhaving one of its ends headed as at ,8, and their opposite ends I screwthreaded to receive winged nuts ll. Through the bottom wall of thechannels 4 and l", the slab is also provided with a seto cause theadjacent end ribs I of one row of slabs to engage or contact with theintermediate ribs 2 of the opposite rows of slabs, thus resulting in anoverlapping of opposed slabs so that the channels 4'' of two adjacent.slabs cooperate with the channel 4 of an opposing slab to providevertically extending tubular passageways il therebetween, while thespaces between the ribs 3 and 5 provide vertically extending elongatedpassagesways it. The passages II may be used as conduits for ventilationor air conditioning, for the disposition of pipes and wiring or forinsulation if, while passages ii .are for the reception of acementitious material to provide load supporting, strengthening andbonding columns for the wall. I

The first course of the oppositely facing rows of slabs are laid on edgeand in end to end abutting relation upon the usual footing or foundationII. The footing Ii has embedded therein, at predetermined spacedintervals, a series of vertically extending guide pins IO, said pinsbeing so spaced as to project within the tubular column spaces ll of thecompleted courses.

In proceeding with a double walled construction, the tubular passagewaysor column spaces II are adapted to receive tubular guide members l'l,.each of the latter having a plugged lower end socketed as at II for thereception of a guide pin it when said tubular guide member is movedvertically downwardly thereover. The guide members ll are provided orformed intermediate their ends with a plurality of equidistantly spacedlongitudinally extending cam faced ribs H which are four in number andpreferably arcuate in cross-section.

The upper ends of the guide members ll, above the ends of the cam facedribs it, are provided with diametrically extending bars or handles 20.The guide members II are secured together at their upper ends by spacedbracing members 2i which may be-detachably connected thereto by bolts22.

Reinforcing rods 22- are adapted to be placed in tubular column spacesl4, in alternate relation to guide members ll and when the latter areremoved, the same may be replaced with other of said reinforcing rods 23and reinforcing pins i2.

In proceeding with the assembly of the precast slabs, to construct adouble-walled building or enclosure, the'footing i5 is first formed inthe usual manner, having vertically extending gu'ide pins i6 embeddedtherein at predetermined spaced intervals.

Then, the tubular guide members ll are vertically positioned, as shownin Fig. 1, and have their lower ends centered on the guide pins Ii,which are, respectively, received in the socketed ends I. of said guidemembers. Guide members I! are placed in alternate column spaces and thereinforcing elements or rods 23, when used, may be disposed in the otheralternate column spaces, as shown in Figure 1.

The guide members are further positioned to have two opposite cam facesextended in the direction of the center line of the wall and the othertwo at right angles to said center line as indicated in Figures 4 and 6.In so positioning the cam faces l0, each is to contact with at leastone, but preferably opposite side walls of its column space ll. Upon thecompletion of this operation, the upper ends of the guide members H andthe reinforcing rods '23 are clamped between bracing members 2|detachably held in position by bolts 22, which bracing members are inturn rigidly braced from outside the wall strucstructure, by means notshown.

Then, the first row or course of :slabs l are placed on edge and inend-abutting relation with their ribs 2 and 5, extending inwardly of thewall structure, with the channels 4 and 4 thereof partially embracingthe guide member i1 and the reinforcing rods 23. Each slab is thusdefinitely and accurately positioned horizontally by reason of thesurfacesof the channels 4 and 4' contacting with the cam ribs It. Anopposite row of similar slabs are then placed on edge in overlappingrelation to the first row of slabs so drawing same together by wingednuts II. This insures the accurate positioning of the first courses bothhorizontally and vertically. At this point in the construction, thereinforcing rods 22 may be positioned inplace whenever it is desirableto employ such rod 22.

The succeeding courses of slabs are placed on the preceding courses instaggered relation thereto, so that column spaces I are continuous in avertical direction throughout the height of the wall. V

As the building of the wall progresses, reinforcing pins i2 are insertedthrough openings Ii into the column spaces ll containing the reinforcingelements 23 which are then filled to the top of each course by pouringconcrete therein. This procedure causes the alternate column spaces llto be formed into binding columns as the construction of the wallprogresses, and the portions of the columns thus formed, harden and tiethe lower courses of .slabs together in a monolithic structure tosupport the increasing weight of the wall as additional courses arelaid. Since each slab contacts or registers with three successive columnspaces, they will be held securely either at their mid-sections or endswhen every alternate column ll has been filled with concrete- When thelast course of slabs has been laid, the

guide members ll are withdrawn. from the tubular column spaces H, byfirst detaching bracing members 2i and then rotating the guide members,by means of bars or handles 20, through an arc of 45 degrees so as torelease the cam faced ribs ll from their points of previous contact withthe walls of the column spaces and to place them opposite thenon-contactible free spaces a: provided by widened areas or cornerportions of the U-shaped channels 4, and l, as shown in dotted lines inFigure 4. Upon removal of the guide members, reinforcing rods 23 andpins i2 are then inserted'in the column spaces I4, and the latter filledby pouring concrete therein, so as to tie or bond the slabs together.

The spaces l3 formed between opposite rows of slabs may be filled withinsulating material l3, or the same may be used as conduits for piping.

wiring, or for air circulating ducts in ventilating and air conditioningsystems Horizontal joints between courses may be filled with mortar asthe building of the wall progresses, while the vertical joints betweenslabs are formed by filling the tubularcolumn spaces It with concrete,as heretofore stated.

After the'concrete in column spaces It has hardened, the temporarytie-rods I are removed, the openings previously receiving said tie-rodsbeing used to assist in bonding plastic coatings to the walls, orplugged with mortar as desired.

The foregoing description has been limited 'to wall structures in thevertical plane. It can be readily seen however that the method ofconstruction is also adapted to structure wherein the center plane ofthe wall structure is at a substantial angle to the true vertical,andthe wall may be constructed at any angle that will allow the concreteor like plastic to flow into the column spaces for forming the permanentcolumns. Therefore, by the disclosure in the drawings, the descriptionand claims hereof, it is contemplated to include a wall structure in aninclined position.

Having thus described my invention, it will be seenthat I have providedan extremely practical pre-cast,slab and the method of assembling same,either of which may be varied for practical uses. Thus, it is to beunderstood that while certain details of construction and the manner inwhich the invention is to be performed, having been described and shownfor purposes of an example, the invention is not to be limited to theexact details of the description and disclosure in the drawingsherewith, because the same may be modified and varied in numerous wayswithin the scope of the present invention, and it is intended that theinvention is to include everything within the scope of the appendedclaims.

That which is claimed is:

l. A pre-cast wall unit comprising a slab having on one face thereof aplurality of spaced parallel transverse ribs, two ofsaid ribs beingpositioned near the center of said slab and forming together with therib supporting face of said slab, between said centrally positionedribs, a substantially U-shaped groove, and single similar ribspositioned adjacent each end of said slab and spaced inwardly therefrom,each of said single end ribs forming together with the adjacent endportion of the rear face of said slab a groove of substantially one-halfU-shaped configuration, the center plane of each of said ribs being norml to said face of the slab, and each of said ribs being of greaterwidth at its base portion which is integral with the face of the slabthan at its free outer end.

2. A pre-cast wall unit comprising a slab having a front and a rear faceand having on the rear face thereof a plurality of transverse parallelspaced ribs extending outwardly therefrom,

each of said ribs being of greater width at itspoint of connection withthe rear face of said slab than at its free outer end, the center planeof each of said ribs being normal to the rear face of the slab, thereduction in rib thickness being continuous on each side of the centerplane thereof from its greater width at the rear, face of said slab tothe free outerend of said rib, all of said ribs being positioned to forma plurality of transversely extending grooves, one of said grooves beingpomtioned substantially centrally of said slab and others of saidgrooves being positioned adjacent the ends of said slab.

3. A wall structure comprising an outer portion and an inner portion,each of said outer portions and inner portions being composed ofaplurality of similar pre-cast slabs, each of said slabs having aplurality of inwardly projecting spaced fins extending from the rearface thereof, the fins of opposite slabs being in contact with eachother in the center vertical plane of the wall structure and cooperatingto form vertical column spaces, said column spaces being filled withconcrete, corrugated metal reinforcing pins extending through said slabsinto the said concrete in the column spaces, the ends of the wall slabsbeing staggered in opposite rows of the same course and staggeredvertically in adjacent courses on each side of the wallstructure, andeach of said slabs being secured to three successive concrete columns bya plurality of reinforcing pins in each column.

4. A wall structure comprising inner and outer walls composed of aplurality of pre-cast slabs,

' said inner. and outer walls being spaced from each other by spacedribs formed on and extending umn spaces engage, the remaining columnspaces being filled with concrete, said wall structure con tainingsubstantially wide spaces between successive column spaces and at leastone of said wide spaces having communicating openings to exterior ductsadapted to the circulation of air.

5. A wall construction comprising vertical substantially cylindricalguide members braced at top and bottom, an inner wall and an'outer wallcomposed of precast slabs, said slabs having ribs extending inwardly andcooperating to form vertical column spaces within the said wallstructure, means for temporarily maintaining said slabsin position, oneof said guide members being encased in each alternate column space, saidguide members each having a plurality of outwardly projecting surfacesthereon arranged at degree intervals on the circumference thereof, saidsurfaces providing guides for the positioning of said slabs, said columnspaces being of such shape that rotation of the said guide memberthrough 45 degrees will increase the clearance between the saidproiecting surfaces and the walls defining said column spaces to permitthe vertical withdrawal of said guide members.

6. A wall construction of the character described wherein a plurality ofvertical guide and bracing members are rigidly secured in line atpredetermined intervals and preformed building slabs are clampedtogether on opposite sides of and encasing said guide members, saidslabs having a plurality of ribs on the inner faces thereof and aplurality of grooves formed by said ribs, said ribs and grooves onadjacent slabs cooperating to form column spaces between said slabs,said guide members being encased in alternate column spaces, said columnspaces not occupied by guide members being filled with concrete, andsaid concrete containing reinforcing pins extending inwardly through theouter surfaces of said slabs, thereby forming a monolithic wallstructure and permitting the removal of the said guide members when thesaid concrete hardens.

'1. A double-walled building structure, comprised of opposed rows ofpre-cast slabs, each having a body of substantially fiat rectangularform, a pair of inwardly projecting vertically extending spaced ribsformed on the rear face of each of said slabs intermediate the ends ofthe latter to provide a groove of substantially U- shaped cross-section,and an inwardly projecting-vertically extending rib formed on the rear 5face of each of said slabs adjacent each of the ends of the latter,whereby all of said ribs of one row of slabs together with similar ribsof opposed rows of slabs form columns and spaces therebetween. 1

8. A guide member for use with a building structure of the character setforth in claim 6,

wherein the guide members are tubular and each has a socketed endandJongitudinally extending cam-faced ribs formed thereon equi-distantlyspaced about the circumference of the exterior surface of the guidemember.

9. A method of forming a wall construction which wall comprisespre-formed block units having channels therein and adapted to bearranged in courses with said channels in alignment to form columnspaces, said method including placing certain of said channels of eachunit in each course in contact with a temporary guide, filling other ofsaid column spaces with a cementitious material to form columns withinsaid units, and inserting through the channel portion of each unittransverse reinforcing pins which extend into the column spaces andbecome anchored or 30 embedded in the cementitious material when thelatter hardens.

10. A method of forming a double-walled construction which wallcomprises preformed wall units having channels therein and adapted to bearranged in courses with said channels in align-, ment to form columnspaces, said method including the steps of placing pre-cast units onopposite sides of a temporary vertical guide with certain of saidchannels of each unit in contact therewith, filling the other channelswith cementitious material to form columns within the wall structure,then removing the temporary guides and filling those aligned channelswith cementitious material.

11 A method of forming a concrete wall construction as set forth inclaim 10, further characterized by temporarily clamping said units ofeach course in position by passing clamping bolts through opposing unitsof each course, removing 5 said temporary clamping bolts when thecementitious material between the respective units is hardened.

12. A method of forming a wall construction comprising preformed wallunits adapted to be 5 arranged in courses and having channels thereinadapted to align to form column spaces whose side walls are at differentdistances from the longitudinal center of said column spaces, saidmethod including placing certain of said chanoo nels of each unit ineach course in contact with a temporary guide so that the shortestdimension of each column space will contact with the guide, fillingother of said channels with cementitious material to form columns withinthe units, paras tially rotating said temporary guide within the columnspacesto remove the same out of contact with the surfaces of the columnspaces and removing the temporary guide.

13. The method of forming double-walled structuresfor buildings or thelike, which includes casting in situ a foundation therefor, supportingspaced guiding elements on the foundation, arranging and temporarilysecuring precast units in staggered and vertically successive courses onthe foundation and around the guiding elements so as to provide confinedcolumn spaces thereabout, removing the guiding elements in a verticaldirection from said column spaces, inserting reinforcing memberstransversely from the exterior of said units into the confined spacesfrom which the guiding elements have been re.- moved, and then fillingsaid confined spaces with a self-hardening plastic.

14. A precast wall slab of plastic material having a front face and arear face and having on the rear face thereof a plurality of transversegrooves, two of said grooves being positioned adjacent to the ends ofsaid slab and each adaptedto surround one fourth of the circumference ofa cylindrical guide member and to make contact with the said guidemember only at the edges of the groove, another groove being positionedcentrally of saidrear face and adapted to surround one half thecircumference of a cylindrical guide member and to make contact with thesaid guide member only at the edges and center of said groove, provisionbeing made by a plurality of regularly spaced holes through the slab forthe insertion of tie rods for the purpose of clamping such slabs onopposite sides of and enclosing the said guide members in the spacesformed by cooperating grooves.

15. A wall structure comprising an outer portion and an inner portion,each of said outer portions and inner portions being composed of aplurality of similar pre-cast slabs, each of said slabs having aplurality of inwardly projecting spaced fins extending from the rearface thereof, the fins of opposite slabs being in contact with eachother in the center vertical plane of the wall structure and cooperatingto'form vertical column spaces, said column spaces being filled withspaces being filled with a self-hardening plastic 1 material andreinforcing pins extending from the outer surface of the slabs into saidplastic material in said column spaces.

CHARLES M. HUNTINGTON.

